NDT EVALUATION CHECKLIST - StacheAir Work 9B Repair Station CD/… · Web viewThe six most...

NOTICEThis document is disseminated under the sponsorship of the United States Department of Transportation in the interest of information exchange. The United States government assumes no liability for the contents or use thereof. The United States government does not endorse products or manufacturers. Trade or manufacturers’ names appear herein solely because they are considered essential to the objective of this training curriculum.

ACKNOWLEDGMENTS

Development of this course was funded by the Federal Aviation Administration Technical Center, Atlantic City, New Jersey under grant number 93G018. The work was performed at the FAA Center for Aviation Systems Reliability at Iowa State University under the guidance of the FAA NDT Training Design Panel. The materials were designed in cooperation with Aircraft Certification Service and Flight Standard Service personnel for training of Aviation Safety Inspectors.

The contributions of the members of the NDT Training Design Panel are gratefully acknowledged: Alfred L. Broz, FAA National Resource Specialist for NDE; Bernie Borenstein, Principle Maintenance Inspector; Flight Standards Service; Lisa J.H. Brasche, CNDE Associate Director, Iowa State University; Carmen S. Delgado, NDI Course Manager, FAA Academy; John M. Fabry, Manager, FAA Technical Center; Robert E. Guyotte, Manager, Engine Certification Branch; Chris J. Heizer, Training Program Analyst, Aircraft Certification Service; Bruce A. Kotzian, Principle Maintenance Inspector; Flight Standards Service; Isabel Kulick, Training Program Analyst, Aircraft Certification Service; Nancy C. Lane, Training Program Analyst, Aircraft Certification Service; and Fred Sobeck, Aging Aircraft Program Manager; Flight Standards Service.

In addition, many members of the aviation industry have supported the development of this course in the form of guidance, materials, overview, and samples. These include members of the Air Transport Association NDT Network, Boeing Commercial Airplane Corporation, Douglas Commercial Aircraft, General Electric Aircraft Engines, Pratt & Whitney Engines, Northwest Airlines, Northwest Airlink, and the Aging Aircraft NDE Validation Center at Sandia National Laboratories.

Course materials were prepared by Lisa Brasche, Associate Director, CNDE and Program Manager for FAA-CASR; and Anita L. Ousley, Training Specialist, FAA-CASR. Many of the CASR staff supported in preparation and review of materials with significant assistance provided by Linda R. Poore, Program Assistant, FAA-CASR; Brian F. Larson, Engineer, CNDE; and Dave Utrata, Engineer, CNDE.

NON DESTR UC TIV E INSPEC TION

(NDI)

EVA LUA TION CHEC KLIST

The NDI evaluation checklist is a tool to be used in certification, audit/evaluation, and surveillance of nondestructive testing facilities. This checklist is designed to provide a standardized approach to evaluate an NDI facility.

The NDI evaluation checklist is organized around five elements which are used to assess the facility’s ability to perform NDI functions. These five elements comprise a systematic NDI evaluation process that can be utilized in evaluation of any NDI organization, from manufacturing to maintenance. The five elements: documentation, organization, environment, calibration, and training, are defined below:

Documentation - written procedures, processes, specifications and/or methods used by air operators or air agencies in the performance and control of NDI activities.

Organization - relationship of NDI organization to management.

Environment - the general physical condition of the facility, e.g., housekeeping, storage, safety, consumable management, equipment.

Calibration - process by which an item is checked against a standard.

Training - methods used and records maintained to train and retrain NDI personnel.

These elements represent the underlying system that needs to be in place for a satisfactory NDI operation. Using the NDI evaluation checklist provides the Aviation Safety Inspector (ASI) with a standardized approach to assess compliance. Not all questions in the checklist need to be addressed in all situations, nor is it necessary to have an affirmative response to all questions. The ASI exercises judgment in determining compliance based on the facility’s ability to present reasonable and defensible response to the issues contained in the checklist.

The checklist is organized in two parts: Application of the Systematic NDI Evaluation Process; and NDI Methods. Application of the Systematic NDI Evaluation Process includes a general section to record pertinent information about the facility, followed by questions applicable at certification, audit/evaluation, and surveillance for each of the five elements. Many of the questions under certification are also applicable during audit/evaluation and surveillance. The NDI Methods section includes specific questions for the six most commonly used techniques: Visual, Liquid Penetrant, Magnetic Particle, Eddy Current, Ultrasonics, and Radiography.

The checklist is provided as a tool to be used in preparation for evaluation of NDI facilities. It is not intended to be used as a checkoff form during on-site visits.

This document is disseminated under the sponsorship of the United States Department of Transportation in the interest of information exchange. The United States government assumes no liability for the contents or use thereof. The United States government does not endorse products

or manufacturers. Trade or manufacturers’ names appear herein solely because they are considered essential to the objective of this document.

Table of Contents

SYSTEMATIC NDI EVALUATION PROCESS

General............................................................................4

Certification.....................................................................5

Documentation......................................................5

Organization..........................................................6

Environment..........................................................7

Calibration.............................................................8

Training.................................................................9

Audit/Evaluation and Surveillance...................................10

Documentation......................................................10

Organization..........................................................10

Environment..........................................................11

Calibration.............................................................11

Training.................................................................11

NDI METHODS

Visual Inspection.............................................................13

Liquid Penetrant Inspection.............................................15

Magnetic Particle Inspection............................................17

Eddy Current Inspection..................................................20

Ultrasonic Inspection.......................................................22

Radiography....................................................................24

G E N E R A L

FACILITY NAME AND ADDRESS:

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

CERTIFICATE NUMBER ________________________________________________________________

CERTIFICATE TYPES:

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

PRINCIPAL CONTACT: ________________________________________________________________________________________________________________________________________________________________________________________________

Type of Inspection(s) Performed

Visual Liquid Penetrant Magnetic Particle

Eddy Current Ultrasonic Radiography

Other____________________________________________________

TYPE OF EVALUATION

Initial certification or approval

Scheduled audit/evaluation

Surveillance

DATE OF CURRENT EVALUATION ________________________________

DATE OF LAST EVALUATION ____________________________________

C E R T I F I C A T I O N

4

Certification involves the evaluation of the manner in which prospective air operators or air agencies intend to conduct business to assure compliance with all applicable regulatory requirements. The process is designed to identify applicants who comply with regulatory requirements and conform to safe practices. The certification process requires completion of three steps: analyze the data, assure its implementation, and verify its use. Since there is limited specific regulatory guidance that focuses on NDI, a systematic NDI evaluation process has been developed to evaluate the initial submittal of data by the facility on the NDI operation to assure compliance.

DOCUMENTATION

Does the facility have a manual?

Does the manual contain an NDI organizational chart?

Does the manual contain or refer to the appropriate NDI specifications for which approval is requested?

Are the NDI specifications current?

Are the NDI specifications available?

Are there provisions in the manual for internal review or evaluation of compliance to the manual?

Are records of such reviews or evaluations kept?

Are there procedures in place to revise the manual?

Are there procedures in the manual for the retention of inspection records?

Does the manual contain procedures that address nonconformities?

Are manuals and procedures available to and used by the qualified personnel?

Does the manual contain controls for subcontracts for NDI services?

Does the manual contain controls for management of NDI products, materials, and consumables?

ORGANIZATION

Is there a separate NDI organization within the facility?

Does the NDI manager or equivalent have direct line authority to the NDI qualified personnel?

Are NDI requirements provided to the NDI inspection personnel by use of written procedures?

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Does the NDI manager, or equivalent, review the quality assurance system to monitor compliance to the FAA approved data?

Are proper shift change procedures in place to assure communication of inspection status and to assure inspection is properly performed and interpreted?

E N V I R O N M E N T

Facility description

NDI work area size ___________________________________

Number of NDI inspectors (by level if appropriate):

Total ______________________________

NDI subcontractors (list subcontractors utilized and type of inspection authorized)________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Type of equipment: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Is the size of the NDI work area sufficient to perform the NDI inspections?

Is there adequate work area for the storage and separation of NDI materials? (equipment, standards, chemicals, supplies)

Is there a method for controlling and segregating nonconforming NDI equipment and materials?

Are appropriate manuals, procedures, and other documentation available for use by qualified personnel?

Are adequate parts handling systems (cranes, hoists, lifts, etc.) available to the inspectors?

Do routing documents specify the operations needed and in what sequence?

Is adequate protection provided to parts during handling and routing?

Is metal-metal contact of finished surfaces prevented during handling?

6

Are obsolete documents removed from inspection areas?

CALIBRATION

Is there a procedure for calibrating inspection devices to certified standards?

Are there procedures for the segregation of functional and nonfunctional equipment?

Are procedures in place to ensure repaired equipment is recalibrated?

Are reference standards properly labeled, stored, and used?

Are independent data available for reference standards, i.e., drawings, metrology, etc.?

Are the calibration methods documented?

Do calibration methods include environment controls, standards to be used, and accuracy requirements?

Are setup verifications performed on all shifts as appropriate?

TRAINING (CLASSROOM , OJT AND DEMONSTRATION OF

PERFORMANCE)

Are training requirements identified in the manual for the methods used?

Are training, qualification, and certification done in accordance with criteria such as:

SNT-TC-1A Recommended Practice for Personnel Qualification and Certification in Nondestructive Testing

Mil Standard 410-E

ATA 105

Other ____________________________________

Are there procedures for maintaining training records for NDI personnel?

Is there a procedure to include OJT requirements and is it recorded?

Is there a procedure to include demonstration of performance and is it recorded?

Is all data pertinent to individual training/certification/recertification on file?

7

Is there a procedure for recertification/decertification of NDI personnel?

8

A U D I T / E V A L U A T I O N & S U R V E I L L A N C E

Audit/evaluation and surveillance are significant components of an ASIs responsibilities. Audit/evaluation includes verification that the certificate or approval holder meets all regulatory requirements and is operating in compliance with material approved during the certification/approval process. Surveillance includes assuring that compliance is maintained in the day-to-day operations of the air agency for the certificate that they hold. There is limited specific regulatory guidance that focuses on NDI. A systematic NDI evaluation process has been developed to evaluate the NDI operation to assure compliance and consists of five elements: Documentation, Organization, Environment, Calibration, and Training. The issues identified in the certification section are also applicable to audit/evaluation and surveillance.

DOCUMENTATION

Have any changes been made to the manual since initial approval or last audit/evaluation?

Were the proper revision procedures followed in making any changes to the manual?

Has retention of required records been met?

ORGANIZATION

Have any organizational changes been made since the original certification/approval or audit/evaluation?

Are the changes included by revision to the manual?

ENVIRONMENT

Have any changes been made to the working environment that would inhibit or enhance the performance of NDI inspections since the original certification/approval or most recent audit/evaluation?

Are the changes included as revisions to the manual?

Are the inspection devices of the type, range, accuracy and precision appropriate to the product or process?

9

CALIBRATION

Are calibration records kept?

Are calibration records current?

Are materials with expiration dates managed using appropriate procedures?

TRAINING

Is the facility in compliance with requirements for its training records and procedures?

Is the facility in compliance with its recertification requirements?

Is the facility in compliance with its decertification requirements?

Are qualified personnel available for all required techniques and at all the required levels called for in the manual?

N O N D E S T R U C T I V E I N S P E C T I O N M E T H O D S

Nondestructive inspection (NDI) involves the use of a collection of techniques that allow a determination of the integrity of a component, material, or structure without compromising the usefulness of the product. NDI is used by the aviation industry for defect detection, geometrical measurement, and materials characterization. The six most commonly used inspection methods are covered in this checklist and include: visual inspection, liquid penetrant inspection, magnetic particle inspection, eddy current inspection, ultrasonic inspection, and radiographic inspection. A brief description is provided for each of the techniques, followed by a series of questions that are applicable in evaluation of an NDI facility that practices the technique, and the items that may be included in a procedure employing the method.

V I S U A L I N S P E C T I O N

Visual inspection is the process of using the eye, alone or in conjunction with various aids, as the sensing mechanism from which judgments may be made about the condition of a unit being inspected.

Are procedures in place to define the visual inspection process?

Are procedures in place to ensure inspection is documented?

Are precautions taken to ensure that procedures that can adversely affect visual inspection are not performed prior to the inspection process?

10

Is adequate lighting available for the tasks at hand?

Is adequate time allowed for eye adaptation when changes in light intensity occur (going from dark to light areas or vice versa)?

Is a training program in place for visual inspection?

Are procedures in place to ensure that visual inspectors possess binocular vision with good visual acuity?

Are inspectors using specific targets rather than scanning a particular area (i.e., looking at individual rivets as opposed to scanning a lap splice)?

Are flashlights of appropriate quality and intensity used for the inspection?

Are appropriate safety approvals in place for use when recommended in hazardous atmospheres?

Are borescopes, fiberscopes, and other remote viewing equipment properly stored and maintained?

Do inspectors have proper training for the instruments they are using?

Written Procedures for Visual InspectionDuring certification, written procedures should be required, which are applicable to the part or group of parts being tested. During audit/evaluation and surveillance, the adherence to the procedures should be verified. Procedures may include the following elements:

Procedure number and date written

Part identification including material and alloy, and routing slip

Sequence of visual examination

Identification of test standards for system performance verification

Areas of the part to be examined

Part preparation

Use of visual tools such as flashlights, calipers, micrometers, rulers, and magnifying devices

Type of visual instruments (videoscopes, borescopes, fiberscopes) and recording device if

appropriate

Acceptance requirements

11

Record keeping and method for marking parts after examination

Operator’s name

Author and reference to original FAA approved data

L I Q U I D P E N E T R A N T

Liquid penetrant inspection is used to reveal surface breaking cracks in solid, nonporous materials. While both fluorescent and nonfluorescent techniques are available, most aviation applications involve the use of fluorescent penetrants in a bulk process. A series of steps involving precleaning, application of penetrant, removal of excess penetrant, application of developer, and examination under appropriate light, and postcleaning, is needed.

Is the proper light (black light or visible light) used for the penetrant inspection?

Is proper light intensity determined on a regular basis?

Are proper dwell times, dry times, and temperatures followed?

Are gages, thermometers, and timers used to control the process adequate?

Are procedures followed properly to ensure that penetrant is not removed from cracks when excess penetrant is being removed from the surface?

Is the examining area free of interfering debris and “stray” fluorescent materials?

Are procedures in place to assure inappropriate mixing of solutions (penetrants, emulsifiers and developers) does not occur?

Are tanks protected from possible contamination?

Are procedures in place to ensure precleaning and postcleaning is performed properly?

Is the correct penetrant sensitivity being used?

Are test panels used to verify system performance?

Are surface preparation procedures properly performed (e.g., paint removal)?

Are process controls in place for each step of the procedure and are they checked at regular intervals?

Is the penetrant solution compared to a standard for brilliance and color?

12

If dry developer is used, is it dry, fluffy and free of fluorescence?

Written Procedures for Liquid Penetrant InspectionDuring certification, written procedures should be required, which are applicable to the part or group of parts being tested. During audit/evaluation and surveillance the adherence to the procedures should be verified. Procedures may include the following elements:


Part identification including material and alloy

Sequence of liquid penetrant examination



Part preparation including method of cleaning

Drying procedure (time and temperature)

Temperature limits of materials and surface of part

Type of liquid penetrant material to be used and the method and equipment to be used for its

application

Dwell time for penetrant solution

Procedure for removal of excess penetrant

Procedure for application of developer including dwell time


Post-cleaning instructions


Inspector’s name

Procedure author and date

13

M A G N E T I C P A R T I C L E

Magnetic particle inspection is used to find surface and near surface defects in ferromagnetic materials. Fluorescent and nonfluorescent, wet and dry methods are available but most aviation applications involve use of the wet fluorescent method in a batch processing system which is the most sensitive. Parts are usually magnetized in at least two directions at right angles to each other and demagnetization of the part is required.

Are procedures in place to ensure that only ferromagnetic materials will be inspected?

Is the correct light type (visible or black light) used?

Are procedures in place to magnetize the component in sufficient orientations to ensure that all flaws are found?

Is a reference standard(s) available to measure magnetic field strength?

Are procedures in place for demagnetization of the part?

Are procedures in place to remove paint or coatings if required?

Is black light intensity checked on a regular basis?

Is the examining area free of interfering debris and “stray” fluorescent materials?

Are appropriate maintenance procedures for the inspection equipment followed as recommended in the equipment manuals or required by the facility’s documentation?

Are surface preparation procedures properly performed (e.g., paint removal)?

Is bath concentration measured using established procedures?

Are reference standards taken through the same procedure as a part, including demagnetization?

Are procedures in place to ensure that particles which have lost their color or have become stuck together are discarded?

Can the magnetization equipment obtain the required amperage specified by the procedures?

Are the solvents used approved by the manufacturer?

Are central conductors used to inspect circular parts if necessary?

Is the equipment capable of adequately demagnetizing the part?

14

Is there a documented cleaning process to be followed prior to inspection?

Does the known defect test part have defects of similar or smaller size than the smallest acceptable size for the part being inspected?

When the defect test part is processed, is the defect revealed?

Does suspension of magnetic particles adequately wet the part?

Is suspension checked for contamination at established intervals?

After processing, are parts cleaned to remove evidence of magnetic substances?

Are parts demagnetized and checked with a field meter?

Are detailed written procedures available for each part?

Is each step of the procedure signed off?

Do adequate procedures exist for calibrating equipment?

Written Procedures for Magnetic Particle InspectionDuring certification, written procedures should be required, which are applicable to the part or group of parts being tested. During audit/evaluation and surveillance the adherence to the procedures should be verified. Procedures may include the following elements:



Sequence of magnetic particle examination



Part preparation

Position instructions of part with respect to magnetizing equipment

Type of magnetizing current and equipment including use of head, coil, yoke, etc

Current level or the number of ampere turns to be used and the duration of its application

15

Type of magnetic particle material to be used and the method and equipment to be used for

its application

Directions of magnetization


Demagnetization and post cleaning instructions

Rust prevention treatments


E D D Y C U R R E N T

Eddy current testing is used to find surface and near surface defects in conductive materials. It is used by the aviation industry for defect detection such as cracks, corrosion damage, and thickness verification, and for materials characterization such as metal sorting and heat treatment verification. Applications range from fuselage and structural inspection, to engines, to landing gear, to wheels and is the technique most often used after visual. Eddy current inspection involves intensive setup and calibration procedures with known reference standards of the same material as the part. Probes of appropriate design and frequency must be used.

Are appropriate probes and instrumentation being used as called for in the established procedure?

Are appropriate procedures being followed to set up the instrument using reference standards of the same material and geometry as the test piece before each inspection?

Is scan direction chosen to ensure that the probe scans across the potential crack direction?

Are recommended templates and guides being used?

Do qualified personnel have proper training for the instrument they are using (meter vs. impedance plane)?

Are inspectors careful to minimize probe wobble during scanning?

If protective tape is used during the inspection, is it also used during setup and calibration?

Are procedures in place to ensure that defective probes are removed from service?

Are recommended maintenance and calibration procedures being followed?

16

Written Procedures for Eddy Current InspectionDuring certification, written procedures should be required, which are applicable to the part or group of parts being tested. During audit/evaluation and surveillance the adherence to the procedures should be verified. Procedures may include the following elements:



Sequence of eddy current examination



Part preparation

Frequency, probe type, scanning speed

Type of eddy current instrument and recording device, if appropriate

Setup procedures



Operator’s name

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U L T R A S O N I C S

Ultrasonic inspection uses high frequency sound waves to interrogate the component for internal flaws via a transmitting transducer. Both single transducer (where one transducer serves as sender and receiver, known as reflection) and dual transducer (where one transducer serves as sender and the others as receiver, known as transmission) methods are used. The ultrasonic method is used to determine the presence of interior flaws, measure thickness or determine material properties. Typical applications require fluid couplants to transmit the sound from the transducers to the part. Both contact (use of gel couplant) and immersion (submerge part in water or other approved fluid) are used.

Are appropriate transducers and couplants being used as called for in the established procedure?

Are appropriate procedures being followed to set up the instrument using appropriate reference standards?

Do inspectors have proper training for the equipment and procedures being utilized?

Are procedures in place to ensure defective transducers and equipment are removed from service?

Are transducers placed properly as defined by the inspection procedure?

Are recommended maintenance and instrument calibration procedures being followed?

Are procedures in place to ensure glycerin is not used on aluminum materials as it causes corrosion?

Are precautions taken to ensure air bubbles do not exist in immersion inspection systems?

Are equipment records available for preventative maintenance checks reflecting frequency, results, and accuracy of axis movements in immersion systems?

Are there sufficient setup standards for all parts being inspected?

Is there a procedure which includes an inspection plan for each part being inspected?

Written Procedures for Ultrasonics InspectionDuring certification, written procedures should be required, which are applicable to the part or group of parts being tested. During audit/evaluation and surveillance the adherence to the procedures should be verified. Procedures may include the following elements:



18

Sequence of ultrasonic examination



Part preparation

Frequency, transducer type, couplant

Type of ultrasonic instrument and recording device if appropriate

Calibration procedures



Operator’s name

R A D I O G R A P H Y

Radiography uses radiation energy to detect variations in x-ray attenuation in the object under test and can be used to detect inclusions, voids, cracks, and changes in geometry or material properties. Two types of radiation energy are typically used by the aviation industry: x-rays which are produced by electronic generators; and, gamma rays which are produced by isotope sources. Radiography can be used to inspect most materials for both surface and internal flaws but orientation of flaw and source is critical.

Does the facility use x-ray radiography (electronic generators)?

Does the facility use gamma radiography (isotope sources)?

Are safety procedures in place for the handling and use of ionizing radiation?

Are radiation areas marked?

Is mandatory regulatory guidance available?

Are written procedures available?

Are procedures which specify tube voltage, tube current, and exposure time or isotope source and exposure time available and adhered to?

Are required film types available and properly handled and stored?

19

Are procedures in place to ensure film is not mishandled or switched?

Are procedures in place to ensure that recommended source to film distances called for in the procedure are used?

Are procedures in place to ensure proper alignment of the x-ray generator with respect to the part being inspected?

Are procedures in place to ensure that film processing chemicals and film are properly stored and used?

Are required image quality indicators (IQIs) available?

Are adequate darkroom facilities available and are they properly maintained and clean?

Are recommended maintenance procedures followed for light boxes and illuminators?

Are evaluation criteria provided which include type, size, shape, orientation, and location of flaw?

Are accept/reject criteria available?

Is adequate handling equipment available for the parts to be tested?

Is the film read and evaluated prior to return to service for the part, plane, or engine?

Is there a program in place to monitor radiation exposure (film badges, dosimeters, survey meters, etc.)?

Are temperature controls in place and operable on processing equipment?

Are timing devices in place and operable on processing equipment?

Are replenishing devices in place and operable on processing equipment?

Is film viewing equipment in good working condition?

For reading radiographs, is background illumination controllable to a maximum of 2.5 foot candles of ambient light?

Is adequate information indicated on the film?

20

Written Procedures for Radiographic InspectionDuring certification, written procedures should be required, which are applicable to the part or group of parts being tested. During audit/evaluation and surveillance the adherence to the procedures should be verified. Procedures may include the following elements:


Description or sketch of object

Material type and thickness

Source to film distance

Part preparation

Film type

Film density

Screen type and thickness

Isotope or x-ray machine identification

Tube current milliamperage or radio isotope source strength

Kilovoltage settings

Exposure time

Film placement

Source position

Critical orientation or defect location instructions

Penetrameter (IQI) and shim thickness

Penetrameter placement

Special masking or filters

Collimator, shielding of field limitation devices

Film processing methods

Standard reference radiographs that may be used



Sign off for the inspector interpretation

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